Assembly of Electronic and Optical Devices

ABSTRACT

A method for operating an assembly tool includes deposing a first component on an assembly surface with a first tool tip of a manipulator having a range of motion defined by a plane and an axis that is substantially normal to the plane, deposing a second component on the assembly surface, changing an orientation of the assembly surface relative to the axis from a first orientation to a second orientation, lifting the first component from the assembly surface with a second tool tip of the manipulator, and deposing the first component on the second component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation application of application Ser. No. 13/459,460filed Apr. 30, 2012.

FIELD OF INVENTION

The present invention relates generally to the assembly of electronicand optical devices, and more specifically, to the assembly ofelectronic and optical devices at oblique angles.

DESCRIPTION OF RELATED ART

Previous electronic assembly tools are designed to assemble componentson horizontal surfaces. Such tools are often capable of aligningcomponents in an x-y plane parallel to a planar working surface or jig.Such tools are capable of applying a precise force while assembling thecomponents along a z-axis, normal to the x-y plane.

BRIEF SUMMARY

According to one embodiment of the present invention, a method foroperating an assembly tool includes deposing a first component on anassembly surface with a first tool tip of a manipulator having a rangeof motion defined by a plane and an axis that is substantially normal tothe plane, deposing a second component on the assembly surface, changingan orientation of the assembly surface relative to the axis from a firstorientation to a second orientation, lifting the first component fromthe assembly surface with a second tool tip of the manipulator, anddeposing the first component on the second component.

According to another embodiment of the present invention a method foroperating an assembly tool includes deposing a first component on anassembly surface with a first tool tip of a manipulator having a rangeof motion defined by a plane and an axis that is substantially normal tothe plane, deposing a second component on the assembly surface, whereinthe second component includes a fiber portion, the fiber portion of thesecond component engaging a corresponding groove in the first component,changing an orientation of the assembly surface relative to the axisfrom a first orientation to a second orientation, and applying a forcewith a second tool tip to the first component along the axis.

Additional features and advantages are realized through the techniquesof the present invention. Other embodiments and aspects of the inventionare described in detail herein and are considered a part of the claimedinvention. For a better understanding of the invention with theadvantages and the features, refer to the description and to thedrawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The subject matter which is regarded as the invention is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The forgoing and other features, and advantages ofthe invention are apparent from the following detailed description takenin conjunction with the accompanying drawings in which:

FIG. 1 illustrates a prior art arrangement of an assembly tool and ajig.

FIG. 2 illustrates another prior art arrangement of an assembly tool anda jig.

FIG. 3 illustrates an exemplary embodiment of a jig that is arranged inan assembly tool.

FIG. 4 illustrates the deposition of a first component on the assemblysurface of the jig.

FIG. 5 illustrates the repositioning of the jig.

FIG. 6 illustrates the arrangement of the assembly tool followinglifting the first component from the assembly surface.

FIG. 7 illustrates the arrangement of the assembly tool following thealignment of the first component with a second component.

FIG. 8 illustrates the deposition of the mating surface of the firstcomponent with the mating surface of the second component.

FIG. 9 illustrates an alternate exemplary method for assembling thefirst component and the second component.

FIG. 10 illustrates the replacement of the tool tip with the tool tipand the repositioning of the jig.

FIG. 11 illustrates the application of a force along the Z-axis ofmotion of the manipulator.

FIG. 12 illustrates an arrangement of the assembly tool that includescomponents of an optical fiber array assembly.

FIGS. 13-15 illustrate an alternate exemplary method for assemblingcomponents of an optical fiber array, in this regard:

FIG. 13 illustrates a side view of the first component and the secondcomponent;

FIG. 14 illustrates a top view of the first component and the secondcomponent along the line 14 of FIG. 13; and

FIG. 15 illustrates the application of a force along the Z-axis ofmotion of the manipulator.

DETAILED DESCRIPTION

With reference now to FIG. 1, a prior art arrangement of an assemblytool 100 and a jig 106 is illustrated. The assembly tool 100 includes amanipulator 102 that is operable to move in the X-Y plane and along theZ-axis. The manipulator 102 is connected to a tool tip 104 that isremovable, and may be exchanged with other tool tips. The tool tip 104is operable to secure and manipulate a first component 101 having amating surface 105 using any suitable securing methods such as, forexample, pneumatic suction, or a mechanical securing fixture. A jig 106is arranged in the assembly tool 100 and is operative to secure a secondcomponent 103 on a planar surface 108 of the jig 106. In operation, thejig 106 remains substantially stationary, while the manipulator 102 isused to pick up the first component 101 precisely position the firstcomponent 101 relative to the second component 103 in the X-Y plane.Once the first component is positioned in the X-Y plane, the manipulator102 positions the first component 101 to engage with or contact a matingsurface 107 of the second component 103 by moving the first component101 relative to the second component 103 along the Z-axis. The assemblytool 100 is capable of precisely maintaining the position of the firstcomponent 101 relative to the second component 103 in the X-Y planewhile applying a precise force to the first component 101 along theZ-axis. The precise force along the Z-axis is used to affect theassembly or joining of the first component 101 with the secondcomponent.

The use of the assembly tool 100 described above is effective whenassembling components having substantially planar mating surfaces thatmay be assembled by applying a force substantially normal the planarsurfaces. However, it is desirable to assemble some components byapplying a force at an oblique angle to the mating surfaces. Theassembly tool 100 is designed to apply a precise force along the Z-axis,as opposed to applying a precise force in the X-Y plane, and typicallydoes not provide adequate control of a force applied in the X-Y plane.Thus, a method for assembling components by applying a force at an angleoblique to the substantially planar mating surfaces is desired.

FIG. 2 illustrates the assembly tool 100 in an arrangement similar tothe arrangement described above in FIG. 1. However, a second component203 includes a feature that defines a corner 205 that is operative toengage a corner 201 of the first component 101. It is desirable to applya force during assembly along the line 220 that defines an oblique angle(θ) relative to the planar mating surface 107 of the second component203. Though the illustrated embodiment shows the corners 201 and 205,the embodiments described herein are not limited to assemblingcomponents having corners of any shape. For example, any type ofcomponents having any shape may be assembled using the embodiments andmethods below to provide a precise force at an oblique angle relative toone of the mating surfaces.

Methods and apparatuses operative to apply a precise force at an obliqueangle relative to one of the mating surfaces of components are describedin FIGS. 3-8 below. In this regard, FIG. 3 illustrates an exemplaryembodiment of a jig 302 that is arranged in an assembly tool 100. Thesecond component 203 is shown disposed on a substantially planarassembly surface 307 of the jig 302. The component 203 may be held inplace on surface 307 using any suitable securing methods such as, forexample, pneumatic suction, or a mechanical securing fixture. Themanipulator 102 is connected to the tool tip 104 having an engagementsurface 301 that defines a plane relatively parallel to a planar surface305 of the first component 101. The tool tip 104 has secured the firstcomponent 101 to the engagement surface 301.

FIG. 4 illustrates the deposition of the first component 101 on theassembly surface 307 of the jig 302. In this regard, the manipulator 102positions the first component on a portion of the assembly surface 307,and the securing means of the tool tip 104 releases the first component101. The component 101 may be secured on surface 307 using any suitablesecuring methods such as, for example, pneumatic suction, or amechanical securing fixture.

FIG. 5 illustrates the repositioning of the jig 302 such that the jig302 is arranged at a desired angle for assembly. The manipulator 102replaces the tool tip 104 with a tool tip 402 that has an engagementsurface 401 that defines a plane that is at an oblique angle (θ)relative to the Z-axis of movement of the manipulator 102. The jig 302is repositioned such that the assembly surface 307 is arranged at theoblique angle θ relative to the Z-axis of movement of the manipulator102 and is parallel to the engagement surface 401 of the tool tip 402.The repositioning of the jig 302 changes the alignment of the firstcomponent 101 and the second component 203 such that the planar surface305 of the first component 101 is substantially parallel to theengagement surface 401 of the tool tip 402.

FIG. 6 illustrates the arrangement of the assembly tool 100 followinglifting the first component 101 from the assembly surface 307 by thetool tip 402.

FIG. 7 illustrates the arrangement of the assembly tool 100 followingthe alignment of the first component 101 with the second component 203in the X-Y plane.

FIG. 8 illustrates the deposition or joining of the mating surface 802of the first component 101 on or with the mating surface 807 of thesecond component 203 by positioning the first component 101 relative tothe second component 203 along the Z-axis of motion of the manipulator102, and applying a desired precise force along the Z-axis. Thepositions of the assembly surface 307, the mating surface 802 of thefirst component 101, and the mating surface 807 of the second component203 relative to the Z-axis of motion of the manipulator 102 provide forthe application of force by the manipulator 102 along the Z-axis at theoblique angle θ relative to the assembly surface 307, the mating surface802 of the first component 101, and the mating surface 807 of the secondcomponent 203. Following the deposition of the first component 101 onthe second component 203, the first component 101 may be released fromthe tool tip 402. The jig 302 may be repositioned such that the assemblysurface 307 is substantially orthogonal to the Z-axis of motion of themanipulator 102 as shown in FIG. 4, and the tool tip 402 may be replacedby the tool tip 104 (of FIG. 2). The assembled first component 101 andsecond component 203 may be lifted by the tool tip 104 and placed in adesired location. A second set of components may be placed on the jig302 in the arrangement shown in FIG. 4, and the process described abovemay be repeated.

FIG. 9 illustrates an alternate exemplary method for assembling thefirst component 101 and the second component 203. In this regard, thefirst component 101 is placed in a desired position on the secondcomponent 203 using the tool tip 104 while the jig 302 is arranged suchthat the assembly surface 307 is substantially orthogonal to the Z-axisof motion of the manipulator 102.

FIG. 10 illustrates the replacement of the tool tip 104 with the tooltip 402, and the repositioning of the jig 302 such that the assemblysurface 307 is arranged at an oblique angle relative to the Z-axis ofmotion of the manipulator 102.

FIG. 11 illustrates the application of a force along the Z-axis ofmotion of the manipulator 102 that is operative to slide or push thefirst component at an oblique angle relative to the Z-axis of motion ofthe manipulator 102 into a desired position on the second component 203and, if desired affect the joining of the first component 101 with thesecond component 203.

The jig 302 of the illustrated embodiments may include any suitableassembly having an assembly surface 307. The jig 302 may include, forexample a planar assembly surface 307 arranged on an actuator that isoperative to change the orientation of the assembly surface 307 relativeto the Z-axis of motion of the manipulator 102 from an orthogonalorientation to an oblique angle that is parallel to the engagementsurface 401 of the tool tip 402.

The components 101 and 203 may include any type of components including,for example, electronic, or electrical components, or optical componentssuch as optical fiber array packaging components.

In this regard, FIG. 12 illustrates an arrangement of the assembly tool100 that includes components of an optical fiber array assembly thathave been manipulated in a similar manner as described above in FIGS.3-7. The optical fiber array assembly includes a first component 1201that is secured by the tool tip 402 and a second component 1203 that isarranged on the assembly surface 307 of the jig 302. The first component1201 of the illustrated embodiment includes at least one optical fiberand may include an optical fiber ferrule. The optical fiber may includea glass (SiO2 with core region doped with various elements such as Ge)and polymers. The second component 1203 may include at least one grooveto secure an optical fiber. The second component 1203 may include apolymer, a dielectric (SiO2, Al2O3, AlN), or a semiconductor material(Si, Ge, GaAs, InP, GaInAsP). The groove include, for example, aU-shaped groove or V-shaped groove. Once the first component has beenlifted by the tool tip 402, the assembly tool 100 is operative toassemble the first component 1201 and the second component 1203 of theoptical fiber assembly in a similar manner as described in FIG. 8 above.

FIGS. 13-15 illustrate an alternate exemplary method for assemblingcomponents of an optical fiber array. The optical fiber array assemblyincludes a first component 1201 and a second component 1203 that arearranged on the assembly surface 307 of the jig 302 while the assemblysurface is arranged in a substantially horizontal position. The firstcomponent includes a ferrule portion 1301 and a fiber portion 1303. Asingle fiber portion is shown in FIGS. 13-15 for simplicity while anoptical fiber array may include a plurality of fiber portions disposedat a uniform pitch between 150 and 500 um and preferably 250 um. Inoperation, once the second component is arranged on the assembly surface307 using similar methods as described above, the first component isplaced on the assembly surface such that each fiber portion 1303 engagesa groove 1305 (e.g., a U-shaped groove or a V-shaped groove) (of FIG.14) using the manipulator 102 (of FIG. 1). FIG. 14 illustrates a topview of the first component 1201 and the second component 1203 along theline 14 (of FIG. 13).

FIG. 15 illustrates the application of a force along the Z-axis ofmotion of the manipulator 102 that is operative to slide or push thefirst component 1201 at an oblique angle relative to the Z-axis ofmotion of the manipulator 102 into a desired position on the secondcomponent 1203 and, if desired affect the joining of the first component1201 with the second component 1203. The relative motion of the firstcomponent 1201 to the second component 1203 moves the fiber portion 1303into a desired position in the grove 1305.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, element components,and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the present invention has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention. Theembodiment was chosen and described in order to best explain theprinciples of the invention and the practical application, and to enableothers of ordinary skill in the art to understand the invention forvarious embodiments with various modifications as are suited to theparticular use contemplated.

The diagrams depicted herein are just one example. There may be manyvariations to this diagram or the steps (or operations) describedtherein without departing from the spirit of the invention. Forinstance, the steps may be performed in a differing order or steps maybe added, deleted or modified. All of these variations are considered apart of the claimed invention.

While the preferred embodiment to the invention had been described, itwill be understood that those skilled in the art, both now and in thefuture, may make various improvements and enhancements which fall withinthe scope of the claims which follow. These claims should be construedto maintain the proper protection for the invention first described.

What is claimed is:
 1. A method for operating an assembly tool, themethod comprising: deposing a first component on an assembly surfacewith a first tool tip of a manipulator having a range of motion definedby a plane and an axis that is substantially normal to the plane;deposing a second component on the assembly surface; changing anorientation of the assembly surface relative to the axis from a firstorientation to a second orientation; lifting the first component fromthe assembly surface with a second tool tip of the manipulator; anddeposing the first component on the second component.
 2. The method ofclaim 1, further comprising applying a force with the second tool tip tothe first component along the axis.
 3. The method of claim 1, whereinthe assembly surface defines an assembly surface plane.
 4. The method ofclaim 3, wherein in the first orientation, the assembly surface plane issubstantially orthogonal to the axis.
 5. The method of claim 3, whereinin the second orientation, the assembly surface plane is obliquerelative to the axis.
 6. The method of claim 4, wherein the first tooltip includes an engagement surface defining a plane substantiallyparallel to the assembly surface in the first orientation.
 7. The methodof claim 5, wherein the second tool tip includes an engagement surfacedefining a plane substantially parallel to the assembly surface in thesecond orientation.
 8. The method of claim 1, wherein the first tool tipincludes an engagement surface defining a plane substantially parallelto an engagement surface of the first component while the assemblysurface is arranged in the first orientation.
 9. The method of claim 1,wherein the second tool tip includes an engagement surface defining aplane substantially parallel to an engagement surface of the firstcomponent while the assembly surface is arranged in the secondorientation.
 10. The method of claim 1, wherein the first componentincludes a component of an optical fiber array.
 11. The method of claim1, wherein the method further includes, securing the first component tothe assembly surface following the deposing the first component on theassembly surface.
 12. A method for operating an assembly tool, themethod comprising: deposing a first component on an assembly surfacewith a first tool tip of a manipulator having a range of motion definedby a plane and an axis that is substantially normal to the plane;deposing a second component on the assembly surface, wherein the secondcomponent includes a fiber portion, the fiber portion of the secondcomponent engaging a corresponding groove in the first component;changing an orientation of the assembly surface relative to the axisfrom a first orientation to a second orientation; and applying a forcewith a second tool tip to the first component along the axis.
 13. Themethod of claim 12, wherein the assembly surface defines an assemblysurface plane.
 14. The method of claim 12, wherein in the firstorientation, the assembly surface plane is substantially orthogonal tothe axis.
 15. The method of claim 12, wherein in the second orientation,the assembly surface plane is oblique relative to the axis.
 16. Themethod of claim 12, wherein the first tool tip includes an engagementsurface defining a plane substantially parallel to the assembly surfacein the first orientation.
 17. The method of claim 12, wherein the secondtool tip includes an engagement surface defining a plane substantiallyparallel to the assembly surface in the second orientation.
 18. Themethod of claim 12, wherein the first tool tip includes an engagementsurface defining a plane substantially parallel to an engagement surfaceof the first component while the assembly surface is arranged in thefirst orientation.
 19. The method of claim 12, wherein the second tooltip includes an engagement surface defining a plane substantiallyparallel to an engagement surface of the first component while theassembly surface is arranged in the second orientation.
 20. The methodof claim 12, wherein the method further includes: securing the firstcomponent to the assembly surface following the deposing the firstcomponent on the assembly surface; and securing the second component tothe assembly surface following the deposing the second component on theassembly surface.